Method of making disposable garments

ABSTRACT

A disposable garment which is formed from foldable sheet material supplied from two converging webs, one web providing the material primarily for the back panel of the garment and the other web providing the material primarily for the garment&#39;&#39;s front panel. As the webs converge, they are sealed together along lines defining the outline of the desired garment. Immediately prior to the sealing step, one of the webs is transversely slit, the length of each slit being less than the width of the web and terminating short of the web&#39;&#39;s longitudinal edges. After the sealing step has taken place, both webs are cut just beyond the sealing lines to free the finished garment, the cutting lines of such final step intersecting the previously formed slit with the result that the finish garment has a divided rear (or front) panel.

United States Patent Breitkopf et al.

Oct. 24, 1972 METHOD OF MAKING DISPOSABLE GARMENTS 3,492,673 2/1970Zamist ..2/243 R Primary ExaminerAlfred R. Guest AttorneyDawson, Tilton,Fallon & Lungmus [5 7 ABSTRACT A disposable garment which is formed fromfoldable sheet material supplied from two converging webs, one webproviding the material primarily for the back panel of the garment andthe other web providing the material primarily for the garments frontpanel. As the webs converge, they are sealed together along linesdefining the outline of the desired garment. 1mmediately prior to thesealing step, one of the webs is transversely slit, the length of eachslit being less than the width of the web and terminating short of thewebs longitudinal edges. After the sealing step has taken place, bothwebs are cut just beyond the sealing lines to free the finished garment,the cutting lines of such final step intersecting the previously formedslit with the result that the finish garment has a divided rear (orfront) panel.

23 Claims, 7 Drawing Figures PATENIEDW 2 I912 3699.591

SHEET 1 [IF 3 INVENTOR. STEPHEN H. BREITKOPF MICHAEL SCADUTO ATT'YSPATENTED um 24 I972 SHEEI 3 BF 3 INVENTOR. R E T K O P F DFU TO STEPHENH. 8 MICHAEL SCA ATT'YS PATENTED 24 I972 3. 6 99,591

SHEU 3 0f 3 INVENTOR.

STEPHEN H BREITKOPF MICHAEL SCADUTO BY" qnll z dMl vu-g ATT'YS METHOD OFMAKING DISPOSABLE GARMENTS BACKGROUND While disposable garments formedof paper, plastic, or relatively inexpensive cloth are becomingincreasingly popular for a wide variety of uses, a particularlyimportant application for such garments is found in the medical andhospital field where disposability (by in- I cmeration) means reduceddangers of cross contamination. However, even for that application it isimportant that the costs of using disposable gowns and other garmentscompare favorably with the costs for conventional reusable counterparts;otherwise patients may be 1 deprived of the increased safety and otherimportant advantages which disposability affords solely because ofeconomic considerations.

SUMMARY The present invention is therefore directed to a relatively lowcost method for producing large quantities of disposable gowns and otherdisposable garments. In that connection, it is a specific object toprovide a method for r producing a gown or other garment which has oneof its panels (either the front or rear panel thereof) divided along itsvertical mid line. Consequently, the garment, despite its disposability,is similar in appearance to a conventional reusable garment and has theadvantages of relatively conventional design without the disadvantageswhich reusability entails.

It is a specific object to provide a method in which garments are diecut from two webs of paper or other sheet material which have beensecured together along predetermined lines or zones by adhesives or, inthe case of some plastic materials, by means of heat sea]- ing. Aparticularly important aspect of the invention lies in the fact thateven though die cutting occurs after the sealing step, one (and onlyone) of the two panels of each finished gown is centrally divided tofacilitate the donning and removal of such garment. Such a result isachieved by preceding the sealing step with a cutting operation in whichone of the webs is slit transversely to a limited extent, each slithaving a length greater than the mid line opening of the ultimategarment but less than the width of the web. Physical integrity of theweb is therefore maintained despite the slitting operation and, becauseof the retained physical integrity, the web may be subjected to thesubsequent sealing and die cutting steps.

Other objects and advantages of the invention will appear as thespecification proceeds.

DRAWINGS FIG. 5 is a perspective view of a disposable garment formed bya modification of the method of FIGS. 1-4',

FIG. 6 is a schematic perspective view illustrating the modified methodfor producing the garment of FIG. 5;

FIG. 7 is a fragmentary sectional view taken along line 77 of FIG. 5.

DESCRIPTION As illustrated most clearly in FIG. 2, the garment to befabricated by the present method may take the form of a gown 10 havingpanels 11 and 12. The two panels are identical except that one of them(panel 12 in the illustrated embodiment) is provided with a mid centraldivision or opening 13. Thus, if panel 12 is to be considered a backpanel, then gown 10 is an open-back gown having a central verticalopening 13 which divides the rear panel into side sections 12a and 12b.In many applications, no fastening means for the respective sidesections is necessary or desired; however, if such fastening means isdesired, then any suitable fastener such as pressure-sensitive tape orconventional tie bands may be used. It is to be understood that whilepanel 12 has been designated as a rear panel, it may just as easilyconstitute a front panel if a front opening gown is desired.

In the illustration given, gown 10 is equipped with sleeve portions 14and a neck recess or opening 15. The two panels are joined adjacenttheir side edges by lines of attachment 16, and above and below thesleeve portions by lines of attachment l7 and 18.

Gown 10 may be formed of paper, plastic, cloth, or any other suitablesheet material having the necessary properties of foldability, strength,and durability. Soft paper is particularly effective because of itsbreathability" or permeability to air and because it may be produced tohave characteristics similar to cloth. If necessary, its strength may beincreased by incorporating reinforcing fibers therein, and otherproperties such as wet strength, moisture resistance, fire resistance,etc. may be imparted by suitable coatings.

The paper or other sheet material is supplied from two rolls l9 and 20as illustrated in FIG. 3. Web 21 is unwound from roll 19, passing firstbetween a pair of draw rollers 22 and 23 and then to a slitting stationA where it passes between rollers 24 and 25. In FIG. 1 it will beobserved that roller 24 is provided with at least one blade 26 whichextends longitudinally of the roller and which has a length less thanthe width of web 21. Roller 25 has an outer surface layer formed ofpolyurethane, rubber, or any other suitable resilient material, andserves as a resilient platten for the slit cutting roller 24.

Since the slits 27 formed in web 21 by blade 26 are shorter than thewidth of the web, and since they terminate well short of thelongitudinal edge of the web, web 21 maintains its physical integritydespite the transverse slits formed therein. Following the formation ofthe slits, the web 21 passes between guide rollers 28 and 29 where it isurged into contact with the second web 30 unwinding from supply roll 20.

Since the two webs come into contact and are joined together as theypass between rollers 28 and 29, station B may be regarded as a bondingstation even though preliminary steps may be performed to make suchbonding possible. Thus, if the webs are to be bonded or joined byadhesive, then the prior application of adhesive to web 30 is necessary.Such an adhesive applying station C is illustrated in FIGS. 1 and 3.

Referring to FIG. 3, it will be seen that web 30 first passes betweendraw rolls 31 and 32. When it reaches the adhesive applying station C,it advances between applicator roller 33 and platten roller 34. As shownin FIG. 1, applicator roller 33 is provided on its cylindrical surfacewith an arrangement of adhesive applying strips 35 arranged in aselected pattern. It will be observed that the specific patternillustrated is the pattern of attachment lines 16-18 previouslydescribed in connection with the garment of FIG. 2; in other words,strips 35 are arranged to contact web 30 and apply adhesive thereto in apattern which defines a portion of the outline of the garment ultimatelyto be formed. Such strips may be formed of rubber, urethane, or anyother suitable (resilient or rigid) material. For purposes of economy,the garment is designed so that the outlines are applied to the web inalternating apposition, thereby keeping material waste to a minimum.Strip portions 35a and 35b apply glue lines 17 to opposite side edgeportions of the web, whereas strips 350 apply glue to the web 30 to formattachment lines 16 and 18.

The term glue" and adhesive have been used interchangably herein and itis to be understood that any suitable adhesive may be used or, asalready described, other bonding means such as heat sealing may beprovided. Where adhesives are used, they may be thermosetting, or may bepressure-sensitive, or may be liquid adhesives of the air-drying type.Thus, a thermosetting resin might be applied at station C and then beactivated by heat at station B or, alternatively, a thermoplastic resinmight be applied at station C and then maintained in a liquid orsemi-liquid state until after the webs have been brought together atstation B. On the other hand, a pressure-sensitive adhesive might beapplied at station C and then served to bond the webs together when theycome into contact at station B. Any conventional pressure-sensitiveadhesive such as rubber cement might be used. Similarly, any of avariety of conventional thermosetting or thermoplastic adhesives mightbe effectively utilized. Particularly effective results have beenachieved, however, by using a conventional water soluble glue oradhesive, such as orinary starch glue.

The manner in which the liquid glue or adhesive is applied to roller 33is conventional. Strips 35 of roller 33 engage the surface of feedroller 36 which is partially immersed in the liquid adhesive carried insupply trough 37. A metering roll 38 engages the surface of roller 36 tosqueeze excess fluid from that roller and to insure an even applicationof fluid to strips 35.

Webs 21 and 30 converge at the bonding station B, web 21 being broughtinto contact with the adhesivetreated surface of web 30 in such a waythat slits 27 extend along the mid line of each garment outlined by theadhesive lines 16-18 on web 30. it is apparent, therefore, that webs 21and 30 must be advancing at precisely the same speed and that the partsmust be proportioned so that slits 27 are formed and spaced to coincideproperly with the garment outlines defined by the glue adhesive lines16-18. Synchronization of all rollers is essential. Since methods andstructure for the synchronization or coordination of power-operatedrollers are well known in the paper (or plastic) handling art, andbecause the illustration of the power driving means for the rollers andits coordinating and synchronizing elements would tend to obscure theinvention rather than clarify it such structure has been omitted fromthe drawings.

The final cutting station is designated generally by the letter D. Tofacilitate drying or curing of the adhesive, suitable heating means (notshown) may be provided between stations B and D. When thermosettingadhesives are used, or when heat sealing techniques are considereddesirable, one or both of the rollers at station B may be heated. ln anycase, the webs 21 and 30 are bonded together along selected lines asthey approach cutting station D. At that station, cutting blades oredges 39 secured to the cylindrical surface or roller 40 cut throughboth of the webs along the outline of the garment and just beyond thelines of adhesion, particularly lines 16 and 18. ln addition, both ofthe webs are cut by the cutting elements of roller 40 to define thebottom edges of the garment and the neck opening 11. With the formationof the neck opening, a small section 41 of waste material is out free.The cutting of the neck opening and the simultaneous cutting which formsthe ends of the sleeves 14 results in the separation or detachment ofside sections 12a and 12b from each other. Thus, it is only at the finalcutting station that the opening 13 first initiated by the formation ofslit 27 is finally completed. The result is an open-back (or openfront)gown which has been formed in an uninterrupted sequence of stepsstarting with the formation of a slit which is shorter than the width ofthe web in which it is formed but longer, or at least as long as, thefinal opening 13 in the finished gown.

The embodiment of the invention illustrated in FIG. 6 is similar to theprocess already described except that webs 21 and 30' are of unequalwidth. In the particular form illustrated, web 30' is the wider of thetwo, having lateral marginal portions which extend a short distancebeyond each of the longitudinal edges of web 21' when the two webs arebrought together at station B. As the webs approach station D, theadhesive-coated marginal portions 100 of web 30' are rolled or foldedinwardly by curved and tapered folding devices 101. The result is thatthe upper edges of the sleeves 14' of the garment 10' are reinforcedwith an extra thickness of material in the form of attachment portions102, thereby strengthening the sleeves and enhancing the appearance ofthe garment. Except for the reinforcing fold 102 along the upper edgesof the sleeves, garment 10 is identical to the garment 10 previouslydescribed.

While in the foregoing two embodiments of the invention have beendisclosed in considerable detail for purposes of illustration, it is tobe understood by those skilled in the art that many of these details maybe varied without departing from the spirit and scope of the invention.

We claim:

1. In a method of making a disposable garment having from and rearpanels, one of such panels having a generally vertical opening extendingthrough its mid zone to facilitate the putting on and removing of suchgarment, the steps of forming a slit across a first sheet of foldablematerial and terminating said slit short of opposite edges of saidsheet, then securing said first sheet to a second sheet of foldablematerial along bonding lines partially defining the outline of a garmenthaving front and rear panels formed by such sheets, said bonding linesbeing oriented so that said slit generally extends through the mid zoneof one of said panels, and thereafter cutting through both of saidsheets along said outline and outwardly of said bonding lines, such lineof cutting intersecting said slit, whereby, said slit becomes an openingin one of said panels of the finished garment to facilitate putting onand removing of said garment.

2. The method of claim 1 in which said slit is substantially straight.

3. The method of claim 1 in which said foldable material is soft pliablepaper and said bonding lines are formed by adhesive.

4. The method of claim 1 in which said foldable material is a non-rigidplastic.

5. The method of claim 1 in which said foldable material is cloth.

6. In a method of making a disposable garment consisting substantiallyentirely of front and rear panels, one of such panels being dividedalong its vertical mid line, the steps of forming a slit across a firstsheet of foldable material and terminating said slit short of oppositeside edges of said sheet, then superimposing said first sheet withrespect to a second sheet of foldable material and securing the sametogether along bonding lines partially defining the outline of a garmenthaving front and rear panels formed by such sheets, said bonding linesbeing oriented so that said slit generally extends along the mid line ofone of said panels, and thereafter cutting through both of said sheetsalong said outline and outwardly of said bonding lines, such line ofcutting intersecting said slit at its opposite ends, whereby, said slitdivides said one of said panels along the full length thereof forfacilitating the donning and removing of said garment.

7. The method of claim 6 in which said slit is formed along asubstantially straight transverse line.

8. The method of claim 6 in which said bonding lines are defined by theapplication of adhesive.

9. In a method of making a disposable garment having front and rearpanels, one of such panels having an opening extending from the top tothe bottom thereof to facilitate the donning and removing of suchgarment, the steps of forming a slit across a first sheet of foldablematerial and terminating said slit short of opposite edges of saidsheet, applying adhesive to a second sheet along lines partiallydefining the outline of a garment, then securing said sheets togetheralong said adhesive lines, and thereafter cutting through both of saidsheets along said outline and outwardly of said adhesive lines, suchline of cutting intersecting at least one end of said slit, whereby,said slit becomes an opening in one of said panels to facilitate donningand removing of said garment.

10. The method of claim 9 in which said last-mentioned cutting step isalong a line intersecting opposite ends of said slit.

11. The method of claim 9 in which said slit is substantially straightand extends along the longitudinal mid line of one of said panels.

12. A continuous method for making disposable garments from twolongitudinally advancing webs of foldable sheet material, comprising thesteps of transversely slitting a first web at longitudinally spacedintervals while terminating each of said slits short of opposite sideedges of said web to maintain the integrity of said web, advancing theslitted web into superimposing engagement with a second web of foldablesheet material and progressively securing said webs together alongbonding lines partially defining garment outlines with each slitextending generally along the mid line of each outline, and thereaftersuccessively cutting through the superimposed webs along said outlinesand outwardly of said bonding lines to separate completely said garmentsfrom said webs, the lines of cutting intersecting said slits, wherebysaid slits become openings extending to the upper and lower edges ofsaid garments.

13. The method of claim 12 in which said slits are formed by a bladecarried by a roller against which said first web advances.

14. The method of claim 12 in which said slits are longer than thevertical dimensions of the finished garment but shorter than the widthof said first web.

15. The method of claim 12 in which each slit is substantially straight.

16. The method of claim 12 in which said step of cutting through saidsuperimposed webs is performed by blades carried by a roller againstwhich said superimposed webs advance.

1?. The method of claim 12 in which there is the step, prior to the stepof superimposing said webs, of applying adhesive to said second webalong lines which thereafter define said bonding lines when said firstand second webs are brought into engagement.

[8. The method of claim 17 in which said adhesiveapplying step isperformed by a roller having an adhesive-applying element which contactssaid second web as said second web advances.

19. The method of claim 12 in which said first and second webs arebrought into superimposing engagement with at least one pair ofcorresponding longitudinal edges thereof disposed in alignment with eachother, said aligned longitudinal edges being bonded during said securingstep and defining edge portions of said garments upon completion of saidcutting step.

20. The method of claim 19 in which said first and second webs are ofsubstantially the same width and are advanced into said superimposingengagement with the longitudinal edges of said first web in alignmentwith the corresponding longitudinal edges of said second web.

21. The method of claim 12 in which said first and second webs arebrought into superimposing engagement with a longitudinal edge portionof one web projecting laterally beyond the longitudinal edge portion ofthe other of said webs, said securing step including the step of foldingthe longitudinal edge portion of said one web over the correspondinglongitudinal edge portion of said other web and bonding said edgeportions together to define a folded reinforced longitudinal edge, saidfolded reinforced longitudinal edge defining reinforced edge portions ofsaid garments upon completion of said cutting step.

22. The method of claim 21 in which said garments are provided withsleeves, said folded reinforced edge portions comprising edges of saidsleeves.

23. The method of claim 21 in which said first and second webs are ofunequal width.

i l i

1. In a method of making a disposable garment having front and rearpanels, one of such panels having a generally vertical opening extendingthrough its mid zone to facilitate the putting on and removing of suchgarment, the steps of forming a slit across a first sheet of foldablematerial and terminating said slit short of opposite edges of saidsheet, then securing said first sheet to a second sheet of foldablematerial along bonding lines partially defining the outline of a garmenthaving front and rear panels formed by such sheets, said bonding linesbeing oriented so that said slit generally extends through the mid zoneof one of said panels, and thereafter cutting through both of saidsheets along said outline and outwardly of said bonding lines, such lineof cutting intersecting said slit, whereby, said slit becomes an openingin one of said panels of the finished garment to facilitate putting onand removing of said garment.
 2. The method of claim 1 in which saidslit is substantially straight.
 3. The method of claim 1 in which saidfoldable material is soft pliable paper and said bonding lines areformed by adhesive.
 4. The method of claim 1 in which said foldablematerial is a non-rigid plastic.
 5. The method of claim 1 in which saidfoldable material is cloth.
 6. In a method of making a disposablegarment consisting substantially entirely of front and rear panels, oneof such panels being divided along its vertical mid line, the steps offorming a slit across a first sheet of foldable material and terminatingsaid slit short of opposite side edges of said sheet, then superImposingsaid first sheet with respect to a second sheet of foldable material andsecuring the same together along bonding lines partially defining theoutline of a garment having front and rear panels formed by such sheets,said bonding lines being oriented so that said slit generally extendsalong the mid line of one of said panels, and thereafter cutting throughboth of said sheets along said outline and outwardly of said bondinglines, such line of cutting intersecting said slit at its opposite ends,whereby, said slit divides said one of said panels along the full lengththereof for facilitating the donning and removing of said garment. 7.The method of claim 6 in which said slit is formed along a substantiallystraight transverse line.
 8. The method of claim 6 in which said bondinglines are defined by the application of adhesive.
 9. In a method ofmaking a disposable garment having front and rear panels, one of suchpanels having an opening extending from the top to the bottom thereof tofacilitate the donning and removing of such garment, the steps offorming a slit across a first sheet of foldable material and terminatingsaid slit short of opposite edges of said sheet, applying adhesive to asecond sheet along lines partially defining the outline of a garment,then securing said sheets together along said adhesive lines, andthereafter cutting through both of said sheets along said outline andoutwardly of said adhesive lines, such line of cutting intersecting atleast one end of said slit, whereby, said slit becomes an opening in oneof said panels to facilitate donning and removing of said garment. 10.The method of claim 9 in which said last-mentioned cutting step is alonga line intersecting opposite ends of said slit.
 11. The method of claim9 in which said slit is substantially straight and extends along thelongitudinal mid line of one of said panels.
 12. A continuous method formaking disposable garments from two longitudinally advancing webs offoldable sheet material, comprising the steps of transversely slitting afirst web at longitudinally spaced intervals while terminating each ofsaid slits short of opposite side edges of said web to maintain theintegrity of said web, advancing the slitted web into superimposingengagement with a second web of foldable sheet material andprogressively securing said webs together along bonding lines partiallydefining garment outlines with each slit extending generally along themid line of each outline, and thereafter successively cutting throughthe superimposed webs along said outlines and outwardly of said bondinglines to separate completely said garments from said webs, the lines ofcutting intersecting said slits, whereby said slits become openingsextending to the upper and lower edges of said garments.
 13. The methodof claim 12 in which said slits are formed by a blade carried by aroller against which said first web advances.
 14. The method of claim 12in which said slits are longer than the vertical dimensions of thefinished garment but shorter than the width of said first web.
 15. Themethod of claim 12 in which each slit is substantially straight.
 16. Themethod of claim 12 in which said step of cutting through saidsuperimposed webs is performed by blades carried by a roller againstwhich said superimposed webs advance.
 17. The method of claim 12 inwhich there is the step, prior to the step of superimposing said webs,of applying adhesive to said second web along lines which thereafterdefine said bonding lines when said first and second webs are broughtinto engagement.
 18. The method of claim 17 in which saidadhesive-applying step is performed by a roller having anadhesive-applying element which contacts said second web as said secondweb advances.
 19. The method of claim 12 in which said first and secondwebs are brought into superimposing engagement with at least one pair ofcorresponding longitudinal edges thereof disposed in alignment with eachother, saId aligned longitudinal edges being bonded during said securingstep and defining edge portions of said garments upon completion of saidcutting step.
 20. The method of claim 19 in which said first and secondwebs are of substantially the same width and are advanced into saidsuperimposing engagement with the longitudinal edges of said first webin alignment with the corresponding longitudinal edges of said secondweb.
 21. The method of claim 12 in which said first and second webs arebrought into superimposing engagement with a longitudinal edge portionof one web projecting laterally beyond the longitudinal edge portion ofthe other of said webs, said securing step including the step of foldingthe longitudinal edge portion of said one web over the correspondinglongitudinal edge portion of said other web and bonding said edgeportions together to define a folded reinforced longitudinal edge, saidfolded reinforced longitudinal edge defining reinforced edge portions ofsaid garments upon completion of said cutting step.
 22. The method ofclaim 21 in which said garments are provided with sleeves, said foldedreinforced edge portions comprising edges of said sleeves.
 23. Themethod of claim 21 in which said first and second webs are of unequalwidth.